MATERIALS | COLOUR AND MASTERBATCH


based pigments were identified which could be processed into a masterbatch. Through this step, the pigments are enclosed in the polymer matrix during gentle processing and protected from subsequent damage.


Right: Broadway Colours has carried out successful trials of an endothermic blowing agent masterbatch


Blowing agents Two UK-based companies have been expanding into blowing agent masterbatches. Broadway Colours says it recently carried out successful trials of an endothermic blowing agent masterbatch developed by its in-house technical team and maintains that its use holds many benefits over more widely available exothermic blowing agents. For example, an endothermic chemical foaming agent is less hazardous as it doesn’t release harmful gasses, and there is less chance of an uncontrolled runaway reaction where excessive heat is generated. The product works by creating a fine foam structure in the material whilst the polymer is in a liquified state. Tiny pockets of gas make the mould- ing material less dense, result- ing in a lighter end compo- nent and a reduction in the volume of the polymer required to manufacture it. Technical Manager


Stephen Rayner says: “Broadway’s new blowing agent masterbatch allows our customers to achieve ‘more for less.’ This product provides a significant weight saving in the final moulded component meaning less polymer is required [and] can offer a double saving [in pack- aging applications] as the moulder is able to reduce polymer costs as well as taxation.” In the trial the masterbatch was dosed at just a 1% addition rate, and this achieved a reduction in weight of over 8% in the end component. There were no measurable differences in the dimensions of the moulding or any perceivable difference when compared to control mouldings produced without the addition of Broadway’s blowing agent. The moulder’s projected figures suggest that using the blowing agent in just two packaging applica- tions can deliver savings of around £110,000 and a polymer reduction of 105 tonnes over a five-year period. When combined with the introduction of recycled PP, the moulder estimates a carbon saving of 58% over the lifecycle of these components. Other advantages are that there are no tooling costs or changes to filling and packaging lines. Broadway, traditionally known as a colour


22 INJECTION WORLD | July/August 2023


masterbatch manufacturer, now also produces custom compounds and performance additives. It is currently researching the use of sustainable, carbon neutral pigments for polymers, and says it is working with academic and commercial partners to exploit existing technology in this field. Another UK company,Wells Plastics, is also an


advocate of blowing agent masterbatch, as Carl Birch, Sales and Marketing Director, explains: “There are two families which can be categorised by their decomposition processes as either exothermic or endothermic. Both types of blowing agent masterbatches can be used to produce a cell structure within the article adding structural integrity and reducing component weight by the replacement of expensive polymer with gaseous decomposition products. Endothermic blowing agent masterbatches, via their mechanism of decomposition, will absorb heat energy from their surroundings, this reduces mould cooling and cycle times. Endothermic blowing agent masterbatches can be added at very low levels. Weight reductions are dependent on the specific article and process, but 5-10% is not unreasonable and cycle time reductions can be around 15–20%.” Birch continues: “It is


worth noting that the use of these blowing agent master-


batches are not limited to polyole- fins. In fact, Wells has produced a


number of products for specific use in


bio-based materials, and also materials which are also compostable, helping lightweight materials which are intrinsically denser than standard polyolefins and often carry a significant premium.”


CLICK ON THE LINKS FOR MORE INFORMATION: � www.eclipsecolours.com � https://riverdaleglobal.com � www.avient.com � www.teknorapex.com � www.ampacet.com � https://natureplast.eu � www.americhem.com � www.techmerpm.com � https://lanxess.com � www.tosaf.com � https://af-color.com � https://broadwaycolours.com � https://wellsplastics.com � www.sunchemical.com


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